Interlocking Cladding Panel and Methods of Use

ABSTRACT

A cladding panel for siding construction extends preferably vertically on a structure. The panel has an outer layer and an insulting layer. The panel may have an interlocking groove structure on one longitudinal edge and a cooperating tongue structure on an opposite longitudinal edge. The interlocking groove portion and interlocking tongue portion may have cooperating geometry such that like panels may be assembled together by engaging the tongue portion of one panel with the interlocking groove portion of another panel. The panels when assembled may be generally flush to one another with generally flat faces. The insulating layers of assembled panels may have cooperating geometry to enable the panels to lie flat against a structure with only the insulating layers contacting the structure.

BACKGROUND AND SUMMARY

The following disclosure relates to interlocking siding used in siding construction on a structure. The siding has an outer layer with front and rear surfaces. The front layer is exposed and the rear layer has an insulating layer mounted thereto. The panels may be arranged generally vertical on the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a section of an interlocking cladding panel as described herein;

FIG. 2 shows an alternate perspective view of the section of the panel of FIG. 1;

FIG. 3 shows a front view of the section of the panel of FIG. 1;

FIG. 4 shows a top view of the section of the panel of FIG. 1;

FIG. 5 shows a right side view of the section of the panel of FIG. 1;

FIG. 6 shows a rear view of the section of the panel of FIG. 1;

FIG. 7 shows a bottom view of the section of the panel of FIG. 1;

FIG. 8 shows a left side view of the section of the panel of FIG. 1;

FIG. 9 shows a top view of like panels of section of cladding prior to assembly;

FIG. 10 shows the like panels of FIG. 9 assembled; and

FIG. 11 shows cross-sectional views of a corner trim piece and mounting piece that may be used in connection with the interlocking panel described herein.

FIG. 12 shows a cross sectional view of the corner trim piece and mounting piece of FIG. 11 mounted on a structure;

FIG. 13 shows cross-sectional views of a double lateral edge trim piece and the mounting piece of FIG. 11 that may be used in connection with the interlocking panel described herein.

FIG. 14 shows a cross sectional view of the double lateral edge trim piece and the mounting piece of FIG. 12 mounted on a structure;

FIG. 15 shows a cross sectional view of a single lateral edge trim piece and the mounting piece of FIG. 12; and

FIG. 16 shows a cross sectional view of the single lateral edge trim piece and the mounting piece of FIG. 15 mounted on a structure.

DETAILED DESCRIPTION

As used herein, the terms “left,” “right”, “top,” “bottom”, “front,” and “rear” are used for convenience of describing elements in the views of the drawings and are not meant to be limiting in any sense.

An interlocking panel 20 is used for a siding construction on a structure 100. The panel 20 has an outer layer 22 and an insulating layer 24. The outer layer 22 has front and rear surfaces 26,28, and the insulating layer 24 is mounted to the rear surface 28 of the outer layer. The insulating layer 24 may be bonded or adhered to the rear surface 28 of the outer layer 22. The insulating layer may provide the panel with an insulation value of R−10. A portion of the outer layer front surface 26 forms a panel face 30. The panel face 30 is preferably flat and defines a plane. The panel face 30 may be exposed when mounted on the structure with the insulating layer disposed against the structure. The outer layer front surface may have a surface texture resembling wood or stone as may be desired. The outer layer 30 may be formed from vinyl or aluminum or other material commonly used for siding construction on a structure.

The panel 20 has a length L and a width W. When mounted on the structure, the panel may be arranged such that the length L is generally vertical relative to the structure and the width W is generally horizontal relative to the structure. The length L has opposite first and second longitudinal sides 32,34 extending along the panel length L. The longitudinal sides are spaced apart to generally define the panel width W. The panel 20 also has opposite first and second lateral sides 36,38 extending across the panel width W. The first and second lateral sides 36,38 are spaced apart and generally define the panel length L. As shown in the drawings, the lateral sides 36,38 form the top and bottom peripheral edges of the panel and the longitudinal sides 32,34 form the left and right peripheral edges. The section of panel shown in the drawings is illustrative and may have any length L or width W and is not limited to the dimensions or relative scale shown in drawings. The length L may be a length approximating the height of a typical one story as used in construction so that one panel may be used to cover the entire height of the story. The width W may be any convenient width considering handling, weight or manufacturing requirements.

The panel first longitudinal edge (i.e., the “right” edge in FIGS. 3 and 4) may have a web 40 disposed generally transverse to the panel face 30. The panel face 30 may be flat and define a plane, and the web 40 may be perpendicular to the panel face. The web 40 may extend in a direction perpendicular to the panel face rearwardly toward the inner insulating layer 24. As shown in the drawings, the outer layer 22 is formed to bend around the insulating layer to define the first longitudinal edge 32 of the panel and comprise the web 40. The web may extend outward from the longitudinal edge 32. The web may have an interlocking groove portion 42. The outer layer 22 may extend from the panel face 30 rearwardly toward the inner insulating layer 24 and after a certain rearward distance reverse directions back toward the front surface 26 of the panel at an acute angle away from the panel longitudinal edge 32 to form the interlocking groove portion 42 with a triangular or tapered cross-section. The first longitudinal edge web 40 may also have a mounting surface portion 44 to enable the panel to be mounted on the structure. The mounting surface portion 44 may be formed in a plane parallel to the plane defined by the panel face 30. The mounting surface portion 44 may have fastener holes (not shown) that extend through the mounting surface portion and a portion of the insulating layer directly behind the mounting surface portion. Alternatively, the mounting surface may be punctured. Mechanical fasteners 46 (FIGS. 9-16) such as screws or nails may be directed through the mounting surface portion to secure the panel to the structure 100. The outer layer 22 may be formed to extend at an acute angle after the interlocking groove portion 42 to form the mounting surface portion 44. A locking projection 48 may also be formed between the groove portion 42 and the mounting portion 44.

The second longitudinal edge 34 (i.e., the left edge in FIGS. 3,4) of the panel 20 may have an interlocking tongue portion 50. The outer layer 20 may be formed to extend in a direction perpendicular to the panel face 30 rearwardly towards the insulating layer 24 to form the interlocking tongue portion. The outer layer 20 may extend from the panel face 30 rearwardly toward the inner insulating layer 24 and after a certain rearward distance reverse direction back toward the front surface of the panel at an acute angle to form a tapered head of the interlocking tongue portion. The tapered head of the interlocking tongue portion 50 may have a geometry that complements a geometry of the interlocking groove portion 42 of the first longitudinal edge to enable like panels to be assembled together. The tapered head of the tongue portion 50 may be configured to engage the locking projection 48 disposed between the first longitudinal edge interlocking groove portion 42 and mounting surface portion 44. The tongue portion 50 and/or groove portion 42 may be formed from a resilient material to enable the tapered head of the tongue portion to be deflected as necessary during insertion of the tongue into the groove to form the interlocked assembly.

The insulating layer 24 may have a notch 60 formed adjacent the panel first longitudinal edge 32. Preferably, the notch 60 accommodates the web and/or the interlocking groove portion 42 of the panel first longitudinal edge 32. To provide maximum insulating capability, the insulating layer 24 may extend adjacent to the mounting surface portion 44 of the first longitudinal edge. The insulating layer may abut the mounting surface portion 44 to form a flat reference surface to enable the panel to be mounted to a structure 100 with mechanical fasteners 46 (FIGS. 9,10). The insulating layer 24 may have a recess 62 adjacent the second longitudinal edge 34. The recess 60 is dimensioned and configured to receive the first longitudinal edge web mounting portion of a like panel when like panels are assembled. As shown in FIGS. 9 and 10, the mounting surface portion 44 of the first longitudinal edge of one of the panels is arranged to fit in the recess 62 of the second panel second longitudinal edge 34. Accordingly, the insulating layers are arranged such that adjacent panels may be mounted flush or in a co-planar manner with only the insulating layer abutting the structure 100.

As shown in the drawings, the web 40 extends along the entire length of the first longitudinal edge 32. Alternatively, the web may be intermittently spaced along the longitudinal edge. Alternatively, the web may extend along a majority of the longitudinal edge. As shown in the drawings, the interlocking tongue portion 50 extends along the entire length of the second longitudinal edge 34. Alternatively, the tongue portion may be intermittently spaced about the second longitudinal edge. In such a configuration the tongue portion may be formed in a pattern that cooperates with the interlocking groove of the first longitudinal edge to enable like panels to be assembled. In an alternative construction, the tongue portion may be intermittently spaced along the second longitudinal edge and the interlocking groove may extend along the entire first longitudinal edge. The interlocking cooperating features of the first and second interlocking edges need only be arranged in a manner to allow like panels to be assembled.

As shown in the drawings, the web 42 and interlocking tongue portions 50 extend perpendicularly to the panel face. Alternatively, the web and tongue portions may be formed at acute angles relative to the panel face. The drawings show the mounting surface portion 44 substantially parallel to the plane defined by the panel face 30. Alternatively, the mounting portion may be formed at an acute angle relative to the panel face.

As described herein, when like panels are assembled, the like adjacent panels are generally coplanar and/or mounted flush relative to each other. Because the panels are mounted flush or coplanar to one another, there is improved streamlining and resistance to wind. Also, because the panels lay flatter against the structure, there is improved streamlining and resistance to wind. The interlocked panels provides less air and water migration. Additionally, because the seams of the interlocked panels may be arranged vertically, any water ingress into the seam may be easily drained. Because the panels are arranged vertically, any variation in color or shade between adjacent panels is less likely to be perceived relative to traditional horizontal siding installations.

FIGS. 11-16 show trim pieces and cooperating mounting pieces that may be used with the panel 20 and/or another type panel of like dimensions. FIG. 11 shows a mounting piece 70 that may be universally used to mount a corner trim piece 72 (FIG. 11), a double lateral edge trim piece 74 (FIG. 13), or a single lateral edge trim piece 76 (FIG. 15). The mounting piece 70 may be secured on the structure 100 and provide an anchor for the corner trim piece 72, the double lateral edge piece 74, and the single lateral edge piece 76.

As shown in FIGS. 11 and 12, the corner trim piece 72 is formed to interlock with the mounting piece 70. The corner trim piece 72 has a tongue portion 80 which may be inserted into a groove portion 82 of the mounting piece 70 to maintain adjacent corner panels 84 (for instance, of the type indicated previously by reference character 20) in a fixed position.

As shown in FIGS. 13 and 14, the double lateral edge trim piece 74 may be interlocked with the mounting piece 70 to provide an aesthetic border between vertically adjacent panels 86,88 (for instance, of the type indicated previously by reference character 20). The double lateral edge trim piece 74 has a tongue portion 90 which is received in the groove portion 82 of the mounting piece 70. A bottom lateral width edge 38 of the top adjacent panel 86 may be received in a top space formed by the assembly, and top lateral width edge 36 of the bottom adjacent panel may be received in a bottom space formed by the assembly.

As shown in FIGS. 15 and 16, the single lateral edge trim piece 76 may be interlocked with the mounting piece 70 to provide an aesthetic border at either the top or bottom lateral width edges of the panels, depending upon its orientation. FIGS. 15 and 16 show the lateral bottom width edge configuration. Rotating the components about the horizontal axis would enable their use in a lateral top edge configuration. The single lateral edge trim piece 76 has a tongue portion 92 which is received in the groove portion 82 of the mounting piece 70. A bottom lateral width edge 38 of a panel 94 (for instance, of the type indicated previously by reference character 20) may be received in a space formed by the assembly.

In view of the foregoing, it will be seen that several advantages are achieved and attained. The embodiments were chosen and described to provide the best examples and their practical application to thereby enable others skilled in the art to best utilize the various embodiments and with various modifications as are suited to the particular use contemplated. As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. 

What is claimed is:
 1. An interlocking cladding panel for siding construction on a structure comprising: an outer layer having opposite front and rear surfaces and an inner insulating layer mounted to the rear surface of the outer layer, at least a portion of the outer layer front surface forming a panel face, the panel face defining a plane, the panel face being exposed and the insulating layer being disposed against the structure when the panel is mounted to the structure, the panel having a length and width with opposite first and second longitudinal edges extending along the panel length and spaced apart to generally define the panel width, and opposite first and second lateral edges extending across the panel width and spaced apart generally defining the panel length, the panel first longitudinal edge having a web disposed generally transverse to the plane defined by the panel face and extending away from the panel face and generally toward the inner insulating layer, the first longitudinal edge web having an interlocking groove portion and a mounting surface portion for mounting the panel on the structure, the panel second longitudinal edge having an interlocking tongue portion disposed generally transverse to the plane defined by the panel face and extending away from the panel face and generally toward the inner insulating layer, the first longitudinal edge interlocking grove portion and the second longitudinal edge interlocking tongue portion having cooperating geometry such that a like panel is enabled to be assembled with the panel by engaging the second longitudinal edge interlocking tongue portion of the like panel with the first longitudinal interlocking groove portion of the panel.
 2. The panel of claim 1 wherein the outer layer comprises the web.
 3. The panel of claim 2 wherein the outer layer comprises the interlocking groove portion.
 4. The panel of claim 1 wherein the outer layer comprises the interlocking tongue portion.
 5. The panel of claim 1 wherein the insulating layer has a notch configured to receive the first longitudinal edge interlocking groove portion.
 6. The panel of claim 1 wherein the insulating layer has a recess adjacent the second longitudinal edge configured to receive the first longitudinal edge web mounting portion when like panels are assembled.
 7. The panel of claim 1 wherein the first longitudinal edge web comprises a locking projection extending between the interlocking grove and mounting portion.
 8. The panel of claim 1 wherein the web extends along a majority of the first longitudinal edge.
 9. The panel of claim 1 wherein the interlocking tongue portion extends along a majority of the second longitudinal edge.
 10. The panel of claim 9 wherein the first longitudinal edge interlocking groove portion extends along a majority of the first longitudinal edge.
 11. The panel of claim 1, wherein the first longitudinal edge mounting portion is substantially parallel to the plane defined by the panel face.
 12. The panel of claim 1, wherein the web is generally perpendicular to the plane defined by the panel face.
 13. The panel of claim 12, wherein the first longitudinal edge mounting portion is substantially perpendicular to the web.
 14. A system comprising: a first interlocking cladding panel for siding construction on a structure, the first panel comprising: an outer layer having opposite front and rear surfaces and an inner insulating layer mounted to the rear surface of the first panel outer layer, at least a portion of the first panel outer layer front surface forming a first panel face, the first panel face defining a plane, the first panel face being exposed and the first panel insulating layer being disposed against the structure when the first panel is mounted to the structure, the first panel having a length and width with opposite first and second longitudinal edges extending along the first panel length and spaced apart to generally define the first panel width, and opposite first and second lateral edges extending across the first panel width and spaced apart generally defining the first panel length, the first panel first longitudinal edge having a web disposed generally transverse to the plane defined by the first panel face and extending away from the first panel face and generally toward the first panel inner insulating layer, the first panel first longitudinal edge web having an interlocking groove portion and a mounting surface portion for mounting the first panel on the structure, the first panel second longitudinal edge having an interlocking tongue portion disposed generally transverse to the plane defined by the first panel face and extending away from the first panel face and generally toward the inner insulating layer; and a second interlocking cladding panel for siding construction on a structure, the second panel comprising: an outer layer having opposite front and rear surfaces and an inner insulating layer adhered to the rear surface of the second panel outer layer, at least a portion of the second panel outer layer front surface forming a second panel face, the second panel face defining a plane, the second panel face being exposed and the second panel insulating layer being disposed against the structure when the second panel is mounted to the structure, the second panel having a length and width with opposite first and second longitudinal edges extending along the second panel length and spaced apart to generally define the second panel width, and opposite first and second lateral edges extending across the second panel width and spaced apart generally defining the second panel length, the second panel first longitudinal edge having a web disposed generally transverse to the second panel face and extending away from the second panel face and generally toward the second panel inner insulating layer, the second panel first longitudinal edge web having an interlocking groove portion and a mounting surface portion for mounting the second panel on the structure, the second panel second longitudinal edge having an interlocking tongue portion disposed generally transverse to the second panel face and extending away from the second panel face and generally toward the second panel inner insulating layer; wherein the first panel first longitudinal edge interlocking grove portion and the second panel second longitudinal edge interlocking tongue portion have cooperating geometry such that the second panel is enabled to be assembled with the first panel by engaging the second panel second longitudinal edge interlocking tongue portion with the first panel first longitudinal interlocking groove portion; and wherein the plane defined by the first panel face is co-planar with the plane defined by the second panel face when the first and second panels are assembled together.
 15. The system of claim 14, wherein a portion of the insulating layers of the first and second panels adjacent the interlocking tongue portion and interlocking groove portion have cooperating geometry.
 16. The system of claim 15, wherein the insulating layer of each panel has a notch configured to receive the first longitudinal edge interlocking groove portion.
 17. The system of claim 15, wherein the second panel insulating layer has a recess adjacent the second panel second longitudinal edge configured to receive the first panel first longitudinal edge web mounting portion when the first and second panels are assembled.
 18. The system of claim 14, wherein the insulating layers of the first and second panels are configured to be solely in contact with a surface of the structure when assembled and mounted on the structure.
 19. The system of claim 14, wherein the outer layer of each panel comprises the web.
 20. The system of claim 14, wherein the outer layer of each panel comprises the interlocking groove portion.
 21. The system of claim 14, wherein the first longitudinal edge web of each panel comprises a locking projection extending between the interlocking grove and mounting portion.
 22. The system of claim 14, wherein the web of each panel extends along a majority of the first longitudinal edge of each panel.
 23. The system of claim 14, wherein the interlocking tongue portion of each panel extends along a majority of the second longitudinal edge.
 24. The system of claim 23, wherein the first longitudinal edge interlocking groove portion of each panel extends along a majority of the first longitudinal edge of each panel.
 25. The system of claim 14, wherein the first longitudinal edge mounting portion of each panel is substantially parallel to the plane defined by the panel face of each respective panel.
 26. The system of claim 14, wherein the web of each panel is generally perpendicular to the plane defined by the panel face of each respective panel.
 27. The system of claim 14, wherein the first longitudinal edge mounting portion of each panel is substantially perpendicular to the web of each respective panel. 